Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
  • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
  • E04B1/92—Protection against other undesired influences or dangers
  • E04B1/94—Protection against other undesired influences or dangers against fire
  • E04B1/941—Building elements specially adapted therefor
  • E04B1/942—Building elements specially adapted therefor slab-shaped
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
  • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups

Definitions

• the invention relates to a fire-resistant, plate-shaped material.
• Flame retardant materials are known.
• the flame retardant is in the Usually achieved by impregnation with liquid solutions. Foam in case of fire these impregnates and thereby cause a delayed ignition of the material surface.
• the object on which the present invention is based is a To provide fire-resistant plate-shaped material having a high fire resistance or fire resistance.
• the factory or on-site coating of the at least one carrier material with at least one Outer layer of a silicate material, which is mixed with a binder increases the fire resistance of the wood material significantly.
• the invention relates further a plate-shaped fire-resistant material with at least one carrier layer made of a wooden material and two outer layers of a silicate, preferably fire-resistant material that is mixed with a binder.
• the carrier layer and at least one, preferably two outer layer provide a plate-shaped Product is that factory in one operation or on site by subsequent Applying the binder mixed with a silicate material is inexpensive to produce, and that has an excellent fire resistance, although the carrier layer is made of combustible material.
• the factory order can readily one or two-sided done, he can with known methods, eg. B. by brushing or rolling.
• the on-site order can also with known methods, in particular by brushing or spraying done and with all the methods used to plaster surfaces.
• the advantage of the factory order is the rational coating.
• the advantage of on-site order is on the one hand the economic coating in that only areas exposed to fire are coated. These are usually the interior facing surfaces.
• the on-site coating allows a completely continuous coating even of edge areas. This is Naturally unreachable with the factory coating. Factory coated Wood-based panels must either be subsequently protected in these edge sections or they remain untreated and then put attack points in one eventual fire
• preferably fire-resistant material is a particulate, mineral material, preferably used phyllosilicates such as vermiculite or perlite.
• silicate materials are in principle all natural or synthetically produced silicates, silicas, silicic acid forms and SiO 2 and its special forms and solids based on these classes of substances suitable.
• natural or synthetically produced siliceous solids such as silicic acids, pyro-silicic acids, quartzes, sands, amorphous or (partly) crystalline alkali metal and alkaline earth metal silicates or aluminosilicates (clay minerals) such as, for example, kaolins, bentonites, talc, mica, feldspar, nepheline, leucites, Olivines, andalusites, kyanites, sillimanites, mullites, vermiculites, perlites, pumice, wollastionites, attapulgites and sepiolites, natural zeolites found in sediments such as clinoptilolite, ereonite and mordenite, and zirconium silicates.
• Silicates their systematics and structures are described, for example, in F. Liebau: “The Systematics of Silicates,” Naturwissenschaften 49 (1962) 481-491, in “Silicon” in KH Wedepohl (ed.): Handbook of Geochemistry, vol. II / 3, chap. 14-A, Springer Verlag, Berlin 1972, pp. 1 - 32 and "Classification of Silicates," in PH Ribbe (ed.): Orthosilicates, reviews in mineralogy, vol. 5, Min. Soc. Am., 1980, pp. 1 - 24 described.
• the phyllosilicates are particularly preferably in its expanded, i. used blown form.
• Especially preferred Phyllosilicates are vermiculites or perlites. Most preferred is vermiculite.
• the silicate materials can be used for the carrier layers coated according to the invention can be used in different particle sizes in the process according to the invention.
• vermiculites can be used in powder form or as granules, wherein the mean particle sizes, for example, at 1 .mu.m to 30 mm, preferably can be at 1 micron to 10 mm in diameter.
• Commercially available vermiculites are used.
• the selection of grain size may be for the on-site coating in particular from the aspect that the grain size in a sense automatically the minimum coating thickness of the coating in a tight Area pretends.
• the use of defined grain sizes thus ensures in the on-site coating the application of coatings that are sized that the desired or predetermined fire resistance can be ensured.
• the grain size is smaller than that To define the layer thickness of the coating required grain size, so can Other particles, preferably inorganic filler particles used for this purpose become. Inorganic filler particles are also nonflammable, impair the function of the coating is not.
• particulate silicate material easily with each other and / or mix with the binder.
• this material is good in mixing and spreading devices that are used to spread layers during production plate-shaped materials are used.
• the siliceous materials are preferred with a solution containing a binder mixed.
• the binder is preferably a silicate Binder.
• modules are known.
• Solutions containing binders in the context of the invention also include stable suspensions, Sols or gels; and colloidal or colloidally disperse solutions, such as Silica sols (silica sols), to be understood.
• Silica sols are colloidal solutions of amorphous silica in water, which are also commonly referred to as silica sols but are referred to briefly as silica sols.
• the silica is present in the form of spherical and surface-hydroxylated particles.
• the particle diameter of the colloid particles is usually 1 to 200 nm, wherein the particle size correlating BET specific surface area (determined by the method of GNSears, Analytical Chemistry Vol. 28, N. 12, 1981-1983, December 1956) at 15 bis 2000 m 2 / g.
• the surface of the SiO 2 particles has a charge which is counterbalanced by a corresponding counterion which results in the stabilization of the colloidal solution.
• silica sols are anionic and alkaline stabilized. Such silica sols have a pH of 7 to 11.5 and contain, for example, small amounts of Na 2 O, K 2 O, Li 2 O, ammonia, organic nitrogen bases, tetraalkylammonium hydroxides or alkali or ammonium aluminates as alkalizing agents.
• Anionic silica sols may also be slightly acidic as semi-stable colloidal solutions.
• silica sols with cationically charged particles by coating the surface with suitable salts, for example Al 2 (OH) 5 Cl.
• suitable salts for example Al 2 (OH) 5 Cl.
• the solids concentrations of silica sols are from 5 to 60 wt .-% SiO 2 .
• the production process for silica sols essentially goes through the production steps of dealkalization of water glass by means of ion exchange, adjustment and stabilization of the respectively desired particle sizes (distribution) of the SiO 2 particles, adjustment of the respectively desired SiO 2 concentration and optionally a surface modification of the SiO 2 particles, such as for example with Al 2 (OH) 5 Cl. In none of these steps do the SiO 2 particles leave the colloidally dissolved state. This explains the presence of discrete primary particles with, for example, high binder efficiency.
• Suitable solutions containing silicate binders in the context of the invention are, for example, soluble alkali metal silicates, silicas, SiO 2 in any desired modifications and forms and mixtures thereof.
• Examples include water glasses, such as the commercially available soda or potassium water glasses, and unmodified and modified silica sols, preferably those commercially available listed.
• Suitable solvents for the silicate binders are in principle all solvents, the no precipitation of the silicate binder or adverse change effect of the binder. They are preferably suitable as solvents for the silicate Binder water or alcohols, for example methanol, ethanol, n-propanol, 2-propanol and higher homologs, and mixtures of these in any mixing ratios. Particularly preferred is water as a solvent for the silicate binder.
• water glass is optionally in admixture with silica, preferably in the form of silica sol, and optionally further additional solvent used.
• a suitable solution containing a silicate binder by mixing alkali silicates or solutions of alkali salts, e.g. Water glass, such as soda or potassium water glass, or other water-soluble Alkali silicates or their solutions, with silica, e.g. in the form of silica sol, and optionally adding additional solvent, optionally under subsequent post-treatment of this solution, e.g. optionally by stirring under Heating, to be produced.
• alkali silicates or solutions of alkali salts e.g. Water glass, such as soda or potassium water glass, or other water-soluble Alkali silicates or their solutions
• silica e.g. in the form of silica sol
• additional solvent optionally under subsequent post-treatment of this solution, e.g. optionally by stirring under Heating
• the binder is elastic according to a particularly preferred embodiment, in particular permanently elastic. This proves especially in the case of the on-site coating of wood-based panels as advantageous because dimensional changes, for example caused by swelling or shrinkage of wood, by an elastic binder can be recorded within specified ranges. Because these shape changes usually in the millimeter range, they can usually by elastic binders are collected. The use of an elastic binder Prevents weak spots from forming, which in the long term reduces the fire resistance could reduce.
• a modified inorganic binder be provided with organic elements, at least In the millimeter range, cracks and gaps can be bridged.
• wood material for the carrier layer are preferably those in the form of known plate-shaped products, including fiberboard, in particular high-density fiberboard (HDF), medium density fibreboard (MDF), chipboard including special shapes like Oriented Strand Board (OSB), plywood and / or solid wood, including Veneer.
• fiberboard in particular high-density fiberboard (HDF), medium density fibreboard (MDF), chipboard including special shapes like Oriented Strand Board (OSB), plywood and / or solid wood, including Veneer.
• HDF high-density fiberboard
• MDF medium density fibreboard
• OSB Oriented Strand Board
• plywood / or solid wood, including Veneer.
• solid wood is not strictly speaking here under the concept of wood-based materials falls within the scope of the invention under this name.
• the aforementioned wood materials are suitable regardless of the binder used, whether organic or inorganic for coating by a binder added silicate material.
• the shield by the at least one, preferably two outer layers is so effective that without
• the fire resistance of the construction can be significantly increased without the carrier layer of wood material itself must be changed constructively. In particular, it does not require the strength to change the wood material, which make technologically extremely complex would.
• the at least two, preferably at least three-layered plate-shaped material can in its construction by adding or inserting at least one further layer be supplemented.
• at least one further layer be supplemented.
• the bending strength of the plate-shaped material can be increased.
• Adding decorative coatings to at least one outer layer is also possible.
• metal or plastic layers e.g. Metal foils
• the fire resistance i. the fire resistance or the strength or the elasticity the plate will be changed.
• Alternatively or in addition to adding more Layers can be added to individual or all layers or layers of aggregates be set to certain properties of the plate-shaped material. So for example, in addition to known flame retardants, foaming agents, preferably those that are flame-retardant, fungicides and / or insecticides as well Adhesive primer for better adhesion decorative cover layers such as wallpaper or the like added be.
• the duration of the fire resistance ie the time until the material ignites, as well as the fire resistance depend among other things also on the layer thickness of the Outer layer off, each pressed onto the carrier layer, glued or in another Way is applied.
• a layer thickness of about 1 mm to about 5 mm preferably from about 3 mm to about 5 mm
• a high fire resistance and fire resistance of at least 30 minutes (F 30) A layer thickness of more than 5 mm, for example, of up to 10 mm ensures even higher fire resistance.
• the fire resistance can reach values of over 60 minutes (F 60) up to more than 90 Minutes (F 90).
• the inventive plate-shaped material has a weight of at least 100 kg / m3, z. B. for one-sided coated insulation boards up to a maximum of 1,000 kg / m3, z. B. for both sides with 20 mm Outer layer coated, high density fiberboard (HDF).
• the strength of Support plates can be selected in a wide range. It can be about 5 mm, for example for particularly dense plates such as HDF plates up to 50 mm, preferably for rather light panels, especially insulation panels with low density range. Usual plate thicknesses are preferably in the range of about 12 mm to about 30 mm selected.
• the fire resistance is influenced although the edge, ie the side surfaces of the plate-shaped material against Are protected by fire. This can be done either through appropriate constructive workmanship done by e.g. Edges are processed on impact. But it can also fire-resistant edge profiles are used, be it from the preceding more defined siliceous, fire-resistant material, such as vermiculite, or other fire-resistant material.
• the side edges are made fire resistant, e.g. by impregnation with Fire retardants, fire or flame retardants.
• the plates are often used for used constructive purposes and tailored later.
• a continuous impregnation Although the carrier layer can be done, but is complex and usually expensive. Preference is therefore given to the use of edge profiles, which subsequently after the Blank can be applied.
• the coating according to the invention applied after processing of the carrier layers on site. she is then applied without gaps and also covers edge areas, recesses in the plates, which are created by subsequent processing of the carrier layers, and others unprotected areas of wood-based materials.
• At least one of the outer layers with a Sealant has been post-treated, which in addition to the fire resistance also the water resistance of the plate according to the invention is increased.
• the invention further relates to a method for producing the inventive plate-shaped material.
• a plate-shaped material according to the above Description can be produced in two different ways. Either a finished plate is coated with at least one outer layer of silicate material or the multilayer plate is in one operation together with the carrier layer pressed.
• the method according to the invention comprises at least the following steps: providing a spreadable mixture of silicate, preferably non-combustible Material and binder for forming an outer layer, the layered arrangement this spreadable mixture on the carrier layer of pressed or unpressed Wood material and the subsequent compression of the spreadable mixture silicate material and binder as outer layer and the carrier layer of wood-based material at elevated pressure and elevated temperature.
• the process can be - as far as the wood material is used without pressing - in Frame of the usual production of wood-based panels without complex additional measures realize, whereby an inexpensive and practicable production of is guaranteed plates according to the invention.
• first the first outer layer scattered then a single or multi-layer wood material layer by scattering devices applied and finally on a second outer layer of silicate Material strewn with binder.
• the thus scattered plate is optionally precompressed and transferred to a press. There is using elevated temperature and increased pressure over a few minutes made the plate.
• Usual production conditions necessary for the production of a plate by sprinkling the apply individual layers require a pressing temperature of at least 140 ° C, preferably from about 160 ° C to 200 ° C.
• the pressing pressure depends on the choice of the silicate material, in particular of whether a blown material is used as silicate material. Moreover In the case of expanded materials, the density of the material may be due to the degree of swelling be different. When using blown materials, such as vermiculite in expanded form, the pressure should preferably about 2 bar, preferably at least 3 bar, more preferably at least 10 bar. However, it can - je according to which materials are to be processed - also pressing pressures of less than 2 bar be beneficial.
• the pressing time be very different.
• the blown Vermiculite is used as a silicate material, it is less than about 15 minutes, preferably less than about 10 minutes, more preferably between about 2 and about 6 minutes.
• the required pressing time depends essentially on the thickness of the press Shift off.
• the silicate material compresses during pressing becomes.
• the particles are mechanically entangled, what the outer layer additionally stabilized, without adverse effects on the properties, such as. Fire resistance.
• the use can of expanded, i. expanded materials, and less compression when Pressing may be preferred.
• expanded materials can further offer the advantage that the Inclusion of air in the plate-shaped material according to the invention the insulation and Improved insulation properties.
• the aftertreatment is carried out with a solution containing a sealant.
• Sealants according to the invention are the binders already mentioned above in question.
• the sealant may be the same as the binder or differ from this one. If the sealant is different from the binder is, the sealant has a relation to the binder higher Module on.
• the modulus of the sealant is preferably at least 5, especially preferably 20 to 1000, most preferably 50 to 200.
• the use of the same Sealing and bonding agent has commercial advantages as only a binder solution must be handled.
• a sealer with higher modulus however, as the binder may have technical advantages, such as higher mechanical Strengths and higher water resistance, bring.
• sealant is different from the binder as a solution of a sealant silica, preferably in the form of silica sol, optionally in admixture with waterglass and optionally used additional additional solvent.
• the solution containing the sealant preferably has a solids content from 5 to 60 wt .-%, particularly preferably 20 to 55 wt .-% based on the total weight the solution.
• the aftertreatment can be done by dipping, soaking, spraying or brushing on and subsequent drying optionally under pressure.
• the duration of the aftertreatment depends on the procedure. In a dipping or drinking process can For example, after only a few seconds, a sufficient intake of sealing liquid be achieved. But there are also longer after-treatment times from up to several hours possible.
• the drying can be just like the one above described intermediate drying of the pressed before the aftertreatment molding at temperatures of 10 to 200 ° C, preferably 20 to 150 ° C take place. She can too for example at room temperature as well as at elevated temperature e.g. in appropriate Drying cabinets, drying rooms, ovens, e.g. High frequency, or by UV curing. Also a drying by freeze drying is conceivable if the aftertreated plate-shaped material is not is damaged. Depending on the drying temperature, the drying time can be adjusted accordingly vary. Drying times of a few minutes or hours are up to several days or even weeks.
• the plate according to the invention can over a conventional wood fiber board continue to provide the advantage of having better sound insulation properties by: it absorbs room sound to a greater extent due to the higher porosity of the surface.
• Blown vermiculite granules with a diameter of 1 mm and a density of 0.1 g / cm 3 is mixed with 10 wt .-% solids content in the binder (here: sodium silicic acid) based on the granules and mixed until the granules evenly with Binder is coated.
• a scattering device About a scattering device, an 8 mm thick layer of vermiculite granules is scattered as the first outer layer of a plate on a conveyor belt.
• the conveyor belt is passed under a second spreader and there are wood chips with typically about 1 to 2 mm thickness, about 3 to 6 mm wide and a length of about 5 to 20 mm in length as a layer 18 mm thick scattered.
• the conveyor belt is guided under a third spreader, from which a second outer layer is sprinkled onto the carrier layer made of wood material, which corresponds to the first outer layer.
• the plate blank now has a thickness of about 34 mm and is in a pre-press compressed to about 20 mm, then transferred to a conventional plate press and at a Pressing temperature of about 160 ° C and a pressure of about 18 bar in 5 minutes to a plate with outer layers of 5 mm thickness and a support layer of 12 mm Crushed starch.
• the granules of vermiculite are at least partly mechanically compressed.
• This plate is for constructive purposes, e.g. for the cladding of drywall or as a substructure for floors used. It has a high fire resistance and a fire resistance of at least 30 minutes up.
• the coating of the carrier layer with at least one outer layer can in preferred Embodiments also take place by the already finished (s) outer layer (s) of a silicate material, which is mixed with a binder, with an already prefabricated Carrier layer is (are) glued.
• At least one outer layer, preferably both outer layers, either before gluing with a sealant after treatment or at least one outer layer, preferably both outer layers, after gluing a post-treatment with a Sealing agents are subjected.
• the carrier layer of wood material according to known methods of Wood material processing produced.
• the outer layer (s) can (can) in one process at least comprising the steps of mixing the binder with the silicate Material, pressing this mixture and optionally after-treatment with a sealant can be produced.
• the mixture of silicate material and the solution containing binder is at 20 to 200 ° C, preferably 20 to 120 ° C, pressed.
• the pressing can be continuous or discontinuously and can according to the usual, known in the art Procedures are performed. For example, in the manufacture be inserted from wood-based panels introduced presses.
• a minimum pressing pressure is sufficient.
• a sufficient initial strength is given if the pressed outer layer is not damaged or even destroyed by the subsequent aftertreatment, ie, for example, does not break apart or completely disintegrate when transported on machine parts and immersion or impregnation with the sealant.
• molding pressures of at least 2 kg / cm 2 are used. However, in other preferred embodiments, pressing pressures less than 2 kg / cm 2 can be used.
• the solvent-containing outer layer thus obtained can after the pressing process and before the post-treatment can be dried.
• This intermediate drying can be done at temperatures from 10 to 200 ° C, preferably 20 to 150 ° C take place.
• one Drying at room temperature as well as drying at elevated temperature e.g. in corresponding drying cabinets, drying rooms, ovens, such as e.g. High frequency, or by UV curing possible.
• a drying by freeze drying is conceivable, provided that the pressed outer layer is not damaged.
• the pressed outer layer before the post-treatment dried. This is particularly advantageous when the strength of the pressed Outer layer should be increased before the aftertreatment. So can also a sufficient Initial strength can be achieved for the subsequent post-treatment. ever after drying temperature and desired degree of drying, the drying time vary accordingly.
• the initial strength can also be increased by gassing with CO 2 .
• This method is known, for example, from the core sand bond with water glasses in the foundry industry.
• the silicate material described for Example 1 becomes Na with a silica sol pasty, spreadable coating agent processed.
• the distended vermiculite granules is used with a diameter of up to 4 mm, resulting in a Layer thickness of 4 mm results.
• This inorganic, non-flammable coating agent is fitted on one side to an 18 mm OSB panel mounted as a room partition Plate thickness applied.
• the 4 mm thick layer of silicate material and Binder gives the OSB board a fire resistance of 30 minutes.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Physics & Mathematics (AREA)
• Electromagnetism (AREA)
• Building Environments (AREA)
• Laminated Bodies (AREA)

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Cited By (4)

Citations (5)

• 2004
  • 2004-05-05 DE DE200410022104 patent/DE102004022104A1/de not_active Withdrawn
• 2005
  • 2005-04-28 WO PCT/EP2005/004548 patent/WO2005108697A1/fr active Application Filing
  • 2005-05-03 EP EP05009692A patent/EP1593791A1/fr not_active Withdrawn

Patent Citations (5)

Non-Patent Citations (1)

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